Download OWNER`S MANUAL - SuperMax Tools
Transcript
Keep This Manual Handy For Quick Reference OWNE R’S MANUAL For SUPERMAX 25 and SUPERMAX 37 (Single Drum); SUPERMAX 25x2 and SUPERMAX 37x2 (Dual Drum) SHOWN WITH OPTIONAL CASTERS, 25” IMPORTANT: BEFORE OPERATING YOUR SUPERMAX, READ THE INSTRUCTIONS IN THIS MANUAL FOR UNPACKING AND SET TING UP YOUR MACHINE. USA 2 SUPERMAX OWNER’S MANUAL CONGRATUL ATIONS CAUTION, SAFET Y FIRST You have made a wise purchasing decision by adding this “Made In USA” machine to your tool line-up. The main purpose in inventing and developing the machine you’ve purchased was to bring a new dimension of productivity to your workshop, be it large or small. Right from the start, our goal at SuperMax Tools has been to manufacture equipment that is capable of providing you with maximum economy, maximum utility, and maximum performance. Your SuperMax Tools drum sander will pay you back many fold in the years ahead by helping you get better results in less time, start to finish. This tool incorporates a bundle of exclusive features which you will appreciate more every time you use it. All SuperMax Tools drum sanders feature patented self-cooling drums and spring-tension abrasive take-up fasteners, as well as sealed and permanently lubricated bearings. The exclusive SuperMax Tools variable-speed power feed conveyor system provides you with ultra-precise control, whether you are surfacing rough-sawn lumber, dimensioning otherwise unusable stock, cleaning up glued panels, or finish sanding either thick stock or the thinnest veneers. SuperMax Tools and its dealers are committed to providing you with innovative solutions, from selecting the right machine to helping you get top performance when you put it to work in your shop. Regardless of how you take advantage of these innovations, we are confident our equipment will help bring you a giant step forward in precision shop productivity. When maintaining and operating this machine, always put safety first. For your own safety, read and understand this owner’s manual before operating this machine. Always heed and follow all normal safety precautions, including the following: • A l w a y s w e a r e y e pr o t e c t i o n w h i l e o p e r a t i n g the sander. • A l w a y s f e e d s t o c k a g a i n s t t h e d r um r o t a t i o n . • Never place hands or fingers under the dr um or dust cover. • K eep hands and clothing away fr om operat ing dr ums. • Never operate the sander without its dust cover or dr um and belt guarding in place. • Always maintain control of boards to avoid kickback; know how to prevent it. • A l w a y s d i s c o n n e c t e l e c t r ical po w e r b e f o r e doing any ser vicing or adjusting of the machine. MODEL IDENTIFICATION Your SUPERMAX drum sander is one of a family of machines from SuperMax Tools designed to help you achieve results comparable to industrial-size sanders at a fraction of the cost. The SUPERMAX is available in 25" or 37" sizes in single drum or dual drum models. For future reference, attach the Model/Serial # Bar Code label below or find the model and serial numbers on the front table mount (#20, page 39) and write them in below. Model: ________________________________ Serial Number: __________________________ Date Purchased: _________________________ Dealer: _________________________________ IMPORTANT : KEEP THIS MANUAL HANDY Please read this manual first. It was designed to help you get the most from your SUPERMAX drum sander. Before unpacking or using the machine, familiarize yourself with its components, features, and basic adjustments by reviewing the following pages. You will find it an invaluable aid in setting up, operating and servicing your machine. If, after reviewing this manual, you still have a problem you can’t solve, please call your SuperMax Tools dealer. MANUAL CONTENTS 3 CONTENTS ABOUT THE SUPERMAX SYSTEM SUPERMAX Nomenclature.........................4 Unpacking Your SUPERMAX Sander ..........5 SET TING UP YOUR SUPERMAX Making Electrical Connections .................6 Connecting Dust Collectors .....................7 Checking For Machine Level ....................7 Checking Drum Alignment ......................7 Checking The Conveyor Belt ...................8 Checking Table Height Controls ..............9 Monthly Maintenance ..............................9 Wrapping Abrasive Strips........................10 OPERATING YOUR SUPERMAX Basic Operating Procedures ....................12 SUPERMAX Operating Controls...............12 Setting The Depth of Cut.......................13 Setting Single or Primary Drum .............13 Setting Secondary Drum (Dual Drum Machines) .......................13 Disengaging The Drums (Dual Drum Machines) .......................14 Selecting SandSmart™ Feed Rates .........14 Using The Depth Gauge.........................15 Selecting Drum Abrasives .......................16 Tips For Maximum Performance ............17 TROUBLESHOOTING YOUR SUPERMAX Troubleshooting Guide: Motors..............19 Troubleshooting Guide: Machine ...........20 Troubleshooting Guide: Operations........22 SERVICING YOUR SUPERMAX Adjusting Height Controls......................24 Adjusting Table Support Castings ...........25 Adjusting Sanding Drums ......................26 Adjusting Tension Rollers .......................28 Replacing Sanding Drums ......................29 Replacing Conveyor Belts .......................31 Replacing V-Belt ....................................32 Rotating/Replacing Drum Bearings ........33 Replacing Electrical Components ...........36 Electrical Diagram ..................................36 SUPERMAX TECHNICAL DATA SUPERMAX Specifications ........................37 Parts List For SUPERMAX Stand...............38 Parts List For Single Drum Assembly......40 Parts List For Dual Drum Assembly .......42 Parts List For Conveyor Assembly...........44 SUPERMAX Accessories & Supplies..........47 FOR YOUR SAFETY: Read all instructions carefully, and note the safety cautions on the opposite page and on the back cover of this manual. 4 SUPERMAX OWNER’S MANUAL ABOUT THE SUPERMAX SYSTEM This manual is designed to help you become familiar with your SUPERMAX drum sander, and to help you take advantage of its exclusive features. By understanding its major components, and how they work together, you will be able to get the most from your investment.The SUPERMAX system is basically made up of the following five major components: 1) precision machined revolving drums wrapped with abrasive strips held by a 2) patented take-up mechanism to process stock fed by the 3) no-give conveyor table which is adjusted by 4) an infinitely variable power feed motor and a 5) convenient height adjustment mechanism. The illustration below shows the major components. DUST COVER SANDING DRUM(S) SECONDARY DRUM ADJ. KNOB H EIGHT AD J U S T M E N T HANDLE TENSION ROLLER MITER GEARS (HEIGHT AD J U S T M E N T ) CONTROL BOX CONVEYOR GEAR MOTOR LEFT (OUTBOARD) SIDE MAIN MOTOR RIGHT (INBOARD) SIDE Fig. 1. SUPERMAX nomenclature. ABOUT THE SUP ERMAX SYSTEM 5 UNPACKING YOUR SUPERMAX Your SUPERMAX sander has been shipped completely assembled from the factory in a cardboard shroud on a pallet and shrink-wrapped in plastic. If any damage has occurred as a result of shipment, notify the transportation company as soon as possible and ask them to make an immediate inspection. Ask for a damage or loss report. Also notify your dealer of any loss or damage during shipment. See enclosed Warranty Statement. Impor tant: To avoid problems and potential damage to the machine, please read through the unpacking instructions below before proceeding to set up the machine in your shop. 1. Unbolt the machine legs from the shipping pallet. Install the rubber-based leveling feet or casters on legs (Fig. 2). The feet and mounting hardware are in the STOP bag packed with your machine. 2. Loosen the hex nut and set screws on the table support castings (Fig. 3). The set screws on the table support castings have been tightened at the factory to eliminate free-play between the table support casting and the column tube during shipment. There are two table support castings on the SUPERMAX, one each for the right and left column tubes. Important: These set screws are tightened for shipping and must be loosened and readjusted before operating either the height adjustment mechanism or the conveyor drive. To properly adjust for operation, loosen each set screw by first loosening its hex nut with an openend wrench and then the set screw with an Allen wrench. Then retighten each set screw with your fingers so it only lightly touches the column tube. Hold each set screw in position with an Allen wrench and retighten the hex nut. Failure to follow these procedures may result in misalignment of the drum(s) and/or the conveyor table. Caution: On the SUPERMAX models do not loosen the set screws on the upper drum support castings. 3. Install the power feed gear motor. Rotate the drive roller on the conveyor system so the flat part of the shaft is down. If necessary, plug the gear motor into an appropriate 220V AC outlet to rotate the motor output shaft coupling so the set screws face downward. Unplug the gear motor. Slide the power feed motor assembly onto the drive roller shaft, aligning the shaft coupling and four mounting holes. Start the four 5/16" hex head bolts on the power feed motor mounting bracket, but do not tighten yet. Next, tighten the set screws in the coupling on the drive roller shaft, making sure they are on the flat of the shaft. Rock the drive roller while tightening the set screws to make sure they are centered properly on the flat. Install the safety shield on the bottom of the assembly with two screws. Then plug in the cord and turn conveyor on full speed. While it is running, tighten the four 5/16" bolts to secure the motor assembly in place. 4. If necessary, adjust the tension of the V-belt between the primary motor and driven pulleys. To do this, loosen the two screws in lower belt guard and loosen the pinch bolt located at the back of the motor support casting. Slide the motor support casting down the column tube until the Vbelt is taut. Tighten the two screws in lower belt guard. Retighten the motor support pinch bolt. TABLE SUPPORT CASTING STAND LEG LEVELING FEET Fig. 2. Leveling feet and mounting hardware. HEX NUT & SET SCREWS Fig. 3. Table suppor t casting and set screws. 6 SUPERMAX OWNER’S MANUAL SET TING UP YOUR SUPERMAX Your SUPERMAX drum sander was adjusted and aligned at the factory, and it has been carefully packed for shipment. However, because of possible stress during transit, the unit should be thoroughly checked before being put to use. This section covers the pre-operational checks you should make after unpacking and final assembly. Unnecessary problems can be avoided if these essential checks are performed before operating the sander. Likewise, performing the recommended monthly maintenance procedures listed at the end of this section will help assure trouble-free service. 10-gauge wire protected by a 30-amp fuse or breaker. Extension cords are not recommended, but if used, should be of at least 10-gauge wire for lengths up to 10' and of at least 8-gauge wire for longer lengths. Three Phase: The drums of SUPERMAX three phase sanders are powered by a 5 hp, 208-230 volt, three phase motor. Three phase machines include a five wire cord but no plug. Three phase SUPERMAX sanders require a minimum dedicated 20amp circuit. Extension cords are not recommended, MAKING ELECTRICAL CONNECTIONS The neutral wire (white) in the power cord to the sander is not used and does not need to be connected on four wire 220V single phase (angle connector) or five wire 220V three phase power connections. Please see wiring diagrams on pages 36 and 37 for details. Single Phase: The drum(s) of all SUPERMAX single phase sanders are powered by a 5 HP, 208230 volt, single phase motor. A NEMA 14-30 plug and cord is supplied. Included with the sander is a NEMA 14-30 flush mount receptacle to use with the sander. Single phase SUPERMAX sanders require a minimum dedicated circuit of Fig. 4. Thermal-overload switch, on some models. 2 4 1 Fig. 5. SUPERMAX Components. 3 4 5 6 6 10 9 7 8 1. Height Adjustment Handle. 2. Adjusting Screw Suppor t. 3. Drum Suppor t Casting. 4. Height Adjusting Screw. 5. Table Suppor t Casting. 6. Adjusting Screw Suppor t. 7. Miter Gear. 8. Motor Suppor t Casting. 9. Transfer Rod. 10. S h a f t C o l l a r s . SET TING UP YOUR SUPERMAX 7 but if used, should be 12-gauge wire for lengths up to 10' and 10-gauge wire for longer lengths. Note: The SandSmart™ Control (Fig. 6) protects both motors from most overload situations. The conveyor motor for feeding stock is infinitely variable from 0-15 ft/min. If the load on the drum motor reaches its optimum, the SandSmart Control will automatically slow the feed rate of the conveyor. When the load is decreased on the main motor, the feed rate will automatically increase but never exceed the manual setting on the dial. DRUM S WITCH SANDSMART CONTROLLER CONNECTING DUST COLLECTORS Dust collection is necessary for all SUPERMAX models. The SUPERMAX 25" models are equipped with one 4""-diameter dust exhaust port at the top of the drum cover. The SUPERMAX 37" models have two 4" dust exhaust ports. To attach the SUPERMAX to your collection system, install 4" hose from your collector. (See Tips For Maximum Performance, page 17 of this manual.) The minimum recommended dust collector capacities at the dust port(s) are: SUPERMAX 25 and SUPERMAX 25x2: 600 CFM; SUPERMAX 37 and SUPERMAX 37x2: 1,200 CFM. For best results, follow the recommendations of the manufacturer of your dust collection equipment. CHECKING MACHINE FOR LEVEL Proper leveling of the machine is essential to achieve continued maximum performance from the SUPERMAX. Before making fine adjustments, place the unit where it will be used in the shop. Then adjust the four leveling feet using a carpenter’s level both across the machine and in line with the machine, placing the level on the conveyor bed. If you have equipped your SUPERMAX with the caster set, do the same after positioning the machine where it will be operated most often. Mark the position of the legs on the floor with tape so it can be returned to the same position. Fig. 6. SandSmar t Controller. Using a flat piece of wood or metal as a thickness gauge, insert it between the conveyor table and the primary (front) drum on the left (outboard) side of the machine (see Fig. 26). Raise the table up so the drum just contacts the thickness gauge. Then, holding up the front tension roller, check at outboard side (Fig. 7) of the drum to see that the drum is parallel to the table. If it is not, disengage CHECKING DRUM ALIGNMENT Your SUPERMAX was shipped from the factory preadjusted with the drum(s) aligned to the conveyor table. Unless the machine was stressed during shipment, only fine adjustment should be necessary. Minor alignment corrections can be done without relieving V-belt tension or adjusting the tension rollers, but should be done without any abrasive strips attached. Fig. 7. Checking dr um alignment (inboard side). 8 SUPERMAX OWNER’S MANUAL AD J U S T M E N T KNOB SHAFT COLLAR I NBOARD MITER GEAR I NDICATOR NEEDLE I NDICATOR SCALE I NDICATOR HEX NUT Fig. 8. Adjusting primar y dr um alignment. Fig. 9. Rear dr um adjustment indicator. the right (inboard) miter gear (see Fig. 8), finely raise or lower the right (inboard) side of the table to achieve parallel alignment of the front (primary) drum. The distance between the conveyor table and both sides of the front drum should be the same. Reinstall the miter gear, aligning the set screw to the flat of the shaft. Dual Drum Models: Before altering this conveyor table position, also check to see that the rear drum (dual drum models only) is likewise parallel to the conveyor table, with both sides at the same height above the table. Using the same thickness gauge, check both sides of the rear drum from the rear of the machine while holding up the rear tension roller. Adjustment of the rear drum is done by using the right and left drum adjustment knobs (see Fig. 9). After the rear drum is adjusted, it is important to reset the rear drum adjustment indicators to zero on both sides. Set the secondary drum adjustment indicators by loosening hex nut, then moving the indicator scale so that the zero mark is directly under the needle, and retightening the hex nut (see Fig. 9). Likewise, zero the indicator for other side of drum. Take care not to overtighten the hex nut of the indicator. This can flare the brass bushing and render the indicator inoperable. Also check that the secondary drum adjustment knobs turn with a slight resistance to avoid any movement during operation. To adjust knob resistance, turn the knob clockwise to reveal the set screw on the shaft collar below the bracket, then loosen the screw. Making sure the adjustment knob is tightly seated on top of the bracket, raise the shaft collar up against the bracket from below and retighten the set screw. Note: The nut of the rear bolt on the rear (secondar y) dr um bearing bracket should be backed off a quar ter-tur n from being fully tightened. This allows the lock washer to be depressed slightly but not completely. This is the pivot point for the rear dr um. CHECKING THE CONVEYOR BELT Conveyor belt tension and tracking adjustments may occasionally be necessary during break-in and normal operation to compensate for belt stretching. Install “Trackers” at this time. See the “Tracker” instruction sheet inside “Tracker” box, for details. “Trackers” are packaged separate on sander. Belt Tension. To adjust the tension of the conveyor belt, first adjust the take-up screw nut (see Fig. 10) on both sides of the conveyor to obtain approximately equal tension on both sides of the belt when taut. Insufficient belt tension will cause slippage of conveyor belt on the drive roller during sanding operation. The conveyor belt is too loose if it can be stopped by hand pressure applied directly to the top of the conveyor belt. Excessive belt tension can result in bent rollers, premature wearing of the SET TING UP YOUR SUPERMAX 9 H EIGHT ADJ. HANDLE DRUM SUPPORT CASTING TABLE SUPPORT CASTING HEX NUT & SET SCREW TAKE-UP SCREW NUT M ITER GEAR Fig. 10. Adjusting conveyor belt tracking. Fig. 11. Table height adjustment mechanism. bronze bushings or belt. Belt Tracking. Belt tracking adjustments are made while the conveyor belt is running. After the proper belt tension is obtained (see above), turn the conveyor unit on and set it at the fastest speed setting. Watch for a tendency of the conveyor belt to drift to one side of the conveyor. To adjust the belt tracking, tighten the take-up screw nut (see Fig. 10) on the side the belt is drifting toward, and loosen the takeup screw nut on the opposite side. Adjusting the take-up screw nuts on either side of the conveyor allows belt tracking adjustments to be made without affecting belt tension. NOTE: Adjust the take-up screw nuts only 1/4 turn at a time. Then allow time for the belt to react to the adjustments before proceeding further. Try to avoid over-adjustments. Make sure wrench is below surface when sanding. the column support tubes. Readjust the set screws just so they eliminate free-play between the table support casting and the column tube. To properly adjust, tighten the set screws (see Fig. 3) only fingertight so they lightly touch the column tubes. Then hold each set screw in position with an Allen wrench and tighten the hex nut. Check the operation of the height adjustment mechanism. If it does not operate smoothly or easily, further adjustments may be necessary. Refer to the servicing section of this manual, which begins on page 24, for further adjustment procedures. CHECKING TABLE HEIGHT CONTROLS The table height and depth of cut is controlled by the height adjustment handle (see Fig. 11). Turning the handle raises or lowers both sides of the table simultaneously by transferring the handle rotation through the miter gear and cross bar assembly. Important: Before using the height adjustment, be sure to loosen both the set screws located on the front of both table support castings (see Fig. 3 and Fig. 11) to allow the table support to slide on both column tubes. These set screws are tightened for shipping and must be loosened and readjusted to allow the table support castings to move freely on MONTHLY MAINTENANCE For best results, perform the following recommended maintenance procedures on a monthly basis: • Lubricate conveyor bushings and check for wear. • Lubricate all moving parts, such as threaded rods, washers, and column tubes. • Clean sawdust from the sandpaper and the conveyor belt. • Blow dust from the inside of sanding drum(s) and the motors. • Check all set screws for tightness on parts such as table support castings, bearings, conveyor coupler, castings, pulleys, and miter gears. 10 SUPERMAX OWNER’S MANUAL WRAPPING ABRASIVE STRIPS Note: When using Pre-Marked™ OR Pre-Cut™ abrasives, not all of the steps below are necessar y. Proper attachment of the abrasive strip to the drum is critical to achieving top performance from your SuperMax Tools drum sander. Abrasive strips do not have to be pre-measured. The end of the roll is first tapered and attached to the left (outboard) side of the drum. Then the strip is wrapped around the drum, and the second taper is made for attachment to the right (inboard) side of the drum. To attach a strip to the drum, follow the procedure below. 1. Mark and cut a taper at one end of the roll as shown in Fig. 12a. Because the tapered end should use most of the left (outboard) slot width, its end must be trimmed (Fig. 12-b and 12-c). Raise the clip lever on the left (outboard) side of the drum (Fig. 12-d). Insert the tapered end through the slot and into the fastener so that it uses most of the width of the slot. Release the clip lever to securely hold the strip end in the fastener. 2. Wrap the strip around the drum, being careful not to overlap the windings. The tapered cut of the strip end should follow the edge of the drum. Continue to wrap the abrasive in a spiral fashion by rotating the drum with your left hand and guiding the strip with your right hand (Fig 12-e). Successive windings of the strip should be flush with previous windings without any overlap. 3. Mark the trailing end of the strip where it crosses the right (inboard) end of the drum (Fig. 12-f ). From this point, cut a taper as was done with the starting edge of the strip. (The taper on the remaining roll can be used as the taper for the starting edge of the next strip to be cut.) rewrap the drum and insert the tapered end through the slot in the right (inboard) end of the drum. Insert the tapered end into the inboard takeup fastener. Pull up on the clip lever to open the clip, and pull the take-up lever to the top as shown (Fig. 12-g). After inserting the strip end, release the clip lever by moving your index finger toward the drum slot. This allows the clip to retain the abrasive while holding the take-up lever in an “up” position. 5. The take-up fastener is designed to automatically take up any slack caused by stretching of the abrasive strip. Impor tant: Position the abrasive strip in the slot with sufficient room between the inside of the slot and the tapered end of the strip to allow it to be pulled into the dr um as needed (Fig. 12-h). Note that not leaving enough space between the strip and the inside of the slot will prevent the take-up fastener from operating properly. 6. The abrasive strip may stretch enough in use to allow the take-up lever to reach its lowest position so it no longer is able to maintain tension on the strip (Fig. 12-i). If this occurs, it will be necessary to reset the take-up lever by raising it, pushing the strip end into the slot, and then releasing the clip lever. Note: A sandpaper cleaning stick may be used to remove deposits and help extend sandpaper life. To use, operate the sanding drum with the dust cover open. (Caution: For your own safety, always wear eye protection while performing sandpaper cleaning, and take all precautions to avoid any contact of hands or clothing with uncovered drums.) Hold the cleaning stick against the rotating drum and move it along the drum surface. It is good procedure to use a shop brush to remove any cleaning stick crumbs from the drums before resuming sanding operations. 4. With the trailing edge of the strip properly cut, CU SANDPAPER STRIP (ABRASIVE SIDE UP ) Also see Fig. 12-b and Fig. 12-c. Fig. 12-a. Marking and cutting taper on strip. T L INE S 15 3/4 " 3" Approx. 3 " SET TING UP YOUR SUPERMAX 11 Fig. 12-b. Trim about 3" from end of cut taper. Fig. 12-c. Trimmed tapered end ready to install. Fig. 12-d. Inser t tapered end into outboard slot. Fig. 12-e. Wrap strip around dr um without overlap. Fig. 12-f. Mark strip where it crosses dr um edge. Fig. 12-g. Inser t tapered end into inboard slot. Fig. 12-h. Allow room inside slot for strip to move. Fig. 12-i. Reset take-up as needed as strip stretches. 12 SUPERMAX OWNER’S MANUAL OPERATING YOUR SUPERMAX Before using your SUPERMAX drum sander, review the previous pages in this manual on initial set-up and adjustment. In this section, you will learn how to operate the machine. Note that connecting the machine to an adequate dust collection system is necessary before operating the unit. BASIC OPERATING P ROCEDURES After you have selected and installed abrasive strips, and connected the machine to a dust collection system, you are ready to begin to use the SUPERMAX. The basic operating procedure for all of the SUPERMAX models is as follows: SECONDARY DRUM AD J U S T M E N T KNOB 1. Set depth of cut. 2. Start drum(s). 3. Start conveyor and select feed rate. 4. Start dust collector system. 5. Feed stock through unit. To feed stock through the SUPERMAX, rest and hold the board to be sanded on the conveyor table, allowing the conveyor belt to carry the board into the drum(s). Once the stock is halfway through, reposition yourself to the outfeed side of the machine to receive and control the board as it exits the unit. FEED RATE CONTROL KNOB H EIGHT AD J U S T M E N T HANDLE DRUM S WITCH Fig. 13. SUPERMAX operating controls. OPERATING YOUR SUPERMAX 13 SET TING THE DEPTH OF CUT Adjusting the SUPERMAX for the proper contact between the abrasive and the stock determines the mechanical depth of cut. Determining the depth o f c u t i s t h e m o s t i m p o r t a n t s e t - u p p r ocedur e before operating the SUPERMAX sander. It may take some experimentation to determine the proper depth of cut, given the variables of abrasive grit, type of wood, and feed rate. For best results, use scrap wood to practice sanding and to develop skill and familiarity with the machine before doing finish work. A good rule of thumb when sanding with grits finer than 80 is to raise the conveyor table so the drum(s) contacts the workpiece but still can be rotated by hand. When using grits coarser than 80 grit, you can raise the conveyor table slightly more. However, a combination of several variables will determine the proper depth of cut to use, including the following: 1. Abrasive type and grit size. 2. Width of the piece being processed. 3. Hardness of the piece. 4. Feed rate of the conveyor belt. If your SUPERMAX is a single drum model, the depth of cut is controlled by the table height adjustment handle which raises or lowers the conveyor table under the drum. If your machine is a dual drum version, the depth of cut of the primary drum is also adjusted by the table height adjustment handle. On dual drum units, the depth of cut of the secondary drum is controlled by the two adjustment knobs (analog indicators) located on both sides of the drum. The drum adjustment knobs allow proper depth of cut with virtually any abrasive grit combinations on the drums. The two drums are normally both used during sanding operations, but either the primary or secondary drum can be used alone. Single or Primar y Drum. To adjust the drum of single drum models, or to adjust the primary drum of dual drum models, set the drum height equal to the thickness of the piece to be processed. This is most easily done as follows: Lower the conveyor table to a depth greater than the thickness of the board. Do not star t the dr um at this time. Start the conveyor and feed the board until it is beneath the drum(s). Raise the conveyor table so the drum(s) contact the board but the drum(s) can still be rotated by hand. Continue to run the board through the machine. This is the setting for the first sanding pass. The depth of cut can be measured on the depth gauge, or by fractions of a revolution of the height adjustment handle. (Note: One revolution of the handle will raise the table 3/32 of an inch; 1/3 of a turn will equal 1/32 of an inch, etc.) Secondar y Drum. On dual drum models, sanding with a different abrasive grit on each drum is possible in a single pass. The coarser abrasive is wrapped on the primary (front) drum for dimensioning and surfacing of the wood, while the finer abrasive is wrapped on the secondary (rear) drum. When used in this way, the secondary drum generally is positioned just slightly lower than the primary drum so it removes the scratches left by the coarser grit on the primary drum (Fig. 14). However, the exact depth of cut of the secondary drum will depend on the specific abrasive grits on each of the drums. The chart on page 14 shows grit combinations and rear drum settings, can also be found under the dust cover of your machine. It suggests settings for various abrasive grit combinations; try these to start and make adjustments as necessary for your work. When adjusting the secondary drum, turn REAR DRUM FRONT DRUM CONVEYOR BELT Fig. 14. Relative positions of dual dr ums. 14 SUPERMAX OWNER’S MANUAL DUAL DRUM GRIT COMBINATIONS & SET TINGS ABRASIVE GRIT GRADES FRONT DRUM GRIT 36 36 36 60 60 80 80 100 120 120 150 REAR DRUM GRIT 36 60 80 80 100 100 120 150 150 180 220 REAR DRUM S ETTING 2.0 2.5 2.5 2.0 1.5 1.0 1.0 0.5 0.5 0.5 0.5 Note: The grits and settings shown are starting sugges tions only. Other combinations and settings are possible, depending on your particular circumstances. both adjustment knobs so that the indicator needles move to the desired setting at the plus (+) end of the scale. (See Fig. 9, page 8.) The depth of cut of the secondary drum should be rechecked each time a different grit combination is used. On dual drum machines, fine-tuning the rear drum settings can help improve performance. Here is a quick way: Raise the rear drum so it is higher than the front drum, with the indicators showing a -3 setting. Place the stock to be sanded under the front drum. Then raise the conveyor table so the front drum contacts the wood, but still can be rotated by hand. Sand the piece with the front drum and stop the machine. Then insert the stock in from the back so it is under the rear drum only. Turn down the rear drum using the plastic adjustment knobs on each side. Lower the rear drum until it contacts the stock but still can be rotated by hand. Use this setting, and note the readings on the depth indicators for future reference. DISENGAGING THE DRUMS On dual drum models, either the primary (front) or secondary (rear) drum may be disengaged so that the other drum can be used alone. To use the pri- mary drum as a single-drum sander, disengage the secondary drum by raising it to the -2 setting on the indicators on both sides. To use the secondary drum alone, lower it to the +4 setting on both sides. In this mode, the table height adjustment handle is used to determine the depth of cut, which will be limited to about 1/32 of an inch before the primary drum starts contacting the work piece. SELECTING SANDSMART FEED RATES Selecting the proper feed rate is essential to proper finish sanding. The variable feed rate control of the conveyor belt adjusts the load on the machine; it can be infinitely adjusted for maximum operating performance. A faster feed rate allows faster sanding but fewer revolutions of the drums per inch of sanding. A slower feed rate provides more revolutions of the drum per inch of sanding to allow a greater depth of cut and smoother sanding. The SandSmart control (See Fig. 15) continuously monitors the load on the drum motor and automatically regulates the speed of the conveyor motor to maintain the highest feed rate without overload. If the load on the drum motor increases, the SandSmart control will decrease the conveyor feed rate and will stop the conveyor under extreme conditions. If the load on the drum decreases, the SandSmart control will increase the feed rate but WILL NOT increase it faster than the manual setting on the switch dial. For abrasive planing and thicknessing, the feed rate can be set at any speed after adjusting for the proper depth of cut. If the load on the drum motor approaches its optimum due to inconsistent stock, the feed rate will automatically slow down. As the load on the drum motor decreases, the feed rate will automatically increase to its original setting. When finish sanding with grits finer than 80, the best finish will be achieved if the conveyor does not change speeds during operation. While the SandSmart control will slow the feed rate when the main motor reaches its optimum, it is advisable to operate below the regulation point. When the red indicator light comes on, the SandSmart control has detected too great a depth of cut and/or too fast a feed rate. This change in conveyor speed may leave a detectable mark on finish surfaces. If a mark is visible, make adjustments by slowing conveyor and/or lessening the depth of cut and run the stock through again. OPERATING YOUR SUPERMAX 15 Begin experimenting with the feed rate set at about 40% to 50% of maximum. The best feed rate will depend on a number of factors, including type of stock, grit and depth of cut used, and whether the stock is feed directly in line with the conveyor bed or at an angle. If you observe a ripple effect on the stock, slow down the feed rate. If the finish is smooth and the machine is not overworking, you can experiment with using a faster feed rate. Also try a faster feed rate if the stock you are working begins to show burn marks. With cherry, hard maple and some other hardwoods, using a shallower depth of cut and a faster feed rate will help minimize burn marks. Slightly angling the stock as it is fed into the machine may also help prevent burning the stock. Because of the wide range of variables, it is important to experiment with your specific conditions and make adjustments to achieve the optimum feed rate. If problems occur, first check the depth of cut and/or adjust the feed rate. Refer to Troubleshooting Your SUPERMAX in this manual, page 19. USING THE DEPTH GAUGE The depth gauge (see Fig. 16) measures the distance between the conveyor table and the sanding drum for thickness dimensioning of boards. To calibrate the depth gauge, raise the conveyor table until the drum(s), wrapped with abrasive, touches the con- veyor table. Loosen the two slotted screws holding the indicator needle to the table mount bracket (Fig. 16). Raise or lower the indicator needle to read at zero and tighten the two slotted screws. USING THE P ROSCALE™ DEPTH GAUGE The ProScale depth gauge (Page 35, Fig. 45A) has its own manual. The ProScale can be calibrated by raising the conveyor until the drum(s) are touching the conveyor and zero the readout. Another calibration method is to sand a piece of wood, measuring the thickness of the wood and change the reading on the ProScale. See included ProScale manual for details on calibrating and operation. USING THE DEPTH STOP A depth stop (Fig. 16) is located on the column tube just above the tale support casting on the right (inboard) side. The depth stop casting has a locking knob located on one side of the casting. To operate the depth stop: Determine desired thickness of sanded part by either referencing the depth gauge or sanding a part and measuring the thickness of the sanded part. At this sanding thickness, position the depth stop along the column tube with the gauge resting on the table support casting and tighten the locking knob on the depth stop. This will give a desired exiting thickness to the material and help prevent under dimensioning. DE P T H GAUGE SCALE DRUM S WITCH I NDICATOR NEEDLE DE P T H GAUGE DE P T H STOP I NDICATOR L IGHT SANDSMART CONTROLLER Fig. 15. SandSmar t Controller and depth gauge. ADJ. SCREWS TABLE SUPPORT CASTING Fig. 16. Depth gauge components, on some models. 16 SUPERMAX OWNER’S MANUAL SELECTING DRUM ABRASIVES It is important to select the proper grit of abrasives for the type of sanding being performed to achieve maximum sanding results. As with any sanding operation, first begin sanding with a coarser grit, depending on the roughness of the stock or the amount of stock to be removed. Then progressively work toward finer grits. The chart below shows the general uses for the various grits. Performax Products offers abrasives in the ten different grits shown. Selecting Abrasive Grits. The amount of stock to be removed is a major consideration when choosing the grit grade to start with. Grits 24, 36, 50, and 60 are primarily designed for stock removal. Grits 24 and 36 will remove the most material in one pass, whether you are doing abrasive planing, cleaning up glued panels, or flattening stock. Grits from 100 through 220 are primarily finishing grits designed to remove the scratch pattern from the previous grit used. For best results, never skip more than one grit grade when progressing through a sanding sequence. For fine work, such as furniture, try not to skip any grit grades during the sanding process. In general, premium quality abrasives such as Genuine Performax abrasives will produce a better finish with a less noticeable scratch pattern. Caution: Grits that are too fine can sometimes burnish the wood and leave a glossy surface which will not accept stains evenly. This will vary by type of wood. Oak, for example, is susceptible to burnishing because of its open pores. Selecting Grit Combinations. The chart shown on page 14 is a general guide to consult when selecting grits to use on dual drum machines and setting the rear drum. This chart is also provided under the dust cover on the SUPERMAX for quick reference. The first column suggests grits for the primary (front) drum of dual drum models, while the second column suggests a corresponding grit to use on the second (rear) drum. The third column suggests depth settings to try on the rear drum, depending on the grit used. The setting values are based on a “0” reading when the drum contacts the work piece but still can be rotated by hand. Note that the grits and settings are starting suggestions only. Other combinations and settings are possible, depending on your particular circumstances. It is a good idea to keep records of the combinations you use and their results. Keeping these records handy will help you select the best combinations of grits for future work. ABRASIVE SELECTION GUIDE GRIT 24 Grit 36 Grit 50 Grit 60 Grit 80 Grit 100 Grit 120 Grit 150 Grit 180 Grit 220 Grit COMMON APPLICATION Abrasive planing, surfacing rough-sawn boards, maximum stock removal, glue removal. Abrasive planing, surfacing rough-sawn boards, maximum stock removal, glue removal. Surfacing and dimensioning boards, trueing warped boards. Surfacing and dimensioning boards, trueing warped boards. Light dimensioning, removal of planer ripples. Light surfacing, removal of planer ripples. Light surfacing, minimal stock removal. Finish sanding, minimal stock removal. Finish sanding only, not for stock removal. Finish sanding only, not for stock removal. OPERATING YOUR SUPERMAX 17 TIPS FOR MAXIMUM PERFORMANCE The versatility designed into the SUPERMAX drum sander allows it to be used for a wide-ranging variety of tasks that will boost the return on your investment. For example, its capabilities range from taking the place of a planer to thickness rough stock, all the way to speeding up fine sanding work often done with slower, dust-generating hand sanders. Learning to use its multiple adjustments and controls will allow you to fine-tune the machine for maximum results, regardless of the job to be done. The best results come from experimenting with different abrasive combinations and machine adjustments to fit the job at hand. Following is a listing of useful tips which can help you improve performance of your sander. Dust Collection. When connecting dust collectors, remember that straight pipe will not restrict airflow as much as flexible tubing. Also, Ys and elbows will restrict airflow less that Ts. When connecting to the dual ports of the SUPERMAX 37 or 37x2, use a larger diameter pipe to the machine, and then split to two 4" hoses connected to the ports. An alternative is to use two separate 4" lines running to the ports; do not use only one 4" line and split it by the machine. Multiple-Piece Sanding Runs. When abrasive planing (or thickness sanding) a run of similar pieces that you want to have the same thickness, it is best to determine the thickness of the thinnest piece and process all pieces to that same thickness. Be aware that the sander will remove cups and crowns in the work piece; consider this when measuring and processing stock to the same thickness. Sanding Multiple Pieces At Once. When sanding multiple pieces simultaneously, make sure to stagger (step) the pieces across the width of the conveyor belt. This provides better contact with the tension rollers. Try to only process multiple pieces of similar thickness. If there is a significant thickness difference, the thinner pieces can slip on the conveyor belt if they do not contact the tension rollers. Also note that pieces thicker than 3/4" should be longer than the minimum normally recommended to prevent tipping of the stock (see Specifications, page 37). Going to longer pieces is especially important when sanding boxes or other tall, short or light stock. Edge Sanding. When edge sanding, the Performax sander will mimic the opposite edge of the stock which is laying on the conveyor belt. Because of this, it is important for the stock edge to have been ripped at the proper angle to the face before the sanding process. When edge sanding stock that is less than 3/4" wide, or more than 2" high, it is good procedure to stack and clamp several pieces together to prevent them from slipping or tipping on the conveyor belt. Sanding Imper fect Stock. When sanding stock with a cup or crown, place the crown up. This will stabilize the stock to help prevent tipping or rocking during sanding. (After the crown has been removed and the top is flat, turn the stock over and sand the opposite side.) To avoid personal injury, take special care when sanding stock that is twisted, bowed, or otherwise varies in thickness from end to end. If possible, support such stock as it is being sanded to keep it from slipping or tipping. Use extra roller stands, help from another person, or hand pressure on the stock, to minimize potentially hazardous situations. Face Frames & Raised Panel Doors. It is very important to have the proper abrasive contact when doing this type of sanding. If the machine is set to take an excessive depth of cut, the result can be a gouge or dip as the drum goes from sanding the rails at full width to sanding just a few inches of width on the stiles. To prevent this problem, for example, make sure that when using abrasives finer than 80 grit the drum is in contact with the wood but can still be spun by hand. If there is room, angling the stock on the conveyor belt can also help. Slowing the conveyor feed when coming to a rail in the stock can help prevent a dip or gouge. This allows the abrasive to work the wider width with less effort, and to achieve better consistency of the finished surface. Stock Feeding Angle. Some pieces, because of their dimensions, will need to be fed into the machine at a 90° angle (perpendicular to the 18 SUPERMAX OWNER’S MANUAL drums). However, even a slight offset angle of the stock will provide for more effective stock removal. The optimum feeding angle for stock removal is about 60° (see Fig. 17). Angling the workpiece for stock removal provides other advantages, such as less loading of certain areas of the drums due to glue lines or mineral streaks in the stock, more even wear of abrasive strips, potentially faster feed rates, and lighter loads on the motor. Note that to get the best final finish, however, the stock should be fed through the machine so it will be sanded in line with the grain of the wood on the final one or two passes. Cleaning Abrasive Strips. Regularly clean the abrasive strips on the drums with commercially available cleaning sticks, following the manufacturer’s directions. (See Fig. 18.) Cleaning sticks are available from your dealer or from SuperMax Tools. When cleaning, also brush the stick crumbs from the drum while it is still rotating. Impor tant: Wear eye protection, tight-fitting clothes and keep alert during this operation to avoid injury. Clothbacked abrasives can be cleaned by soaking in paint thinner or mineral spirits for 20 minutes to 1 hour, then using a brush to remove any build-up or burns. Dry the abrasive strips completely before reuse. In some cases build-ups resulting from burns can be removed with Plexiglas held on edge Fig. 17. Offset stock feeding angle. over a rotating drum. Have dust collection turned on when cleaning. Stretching Abrasive Life. When sanding metal or solid surface, MDF, or particle board, ceramic abrasive (Regalite™) will last longer than aluminum oxide and also allow a more uniform finish. Abrasive life can also be increased on SUPERMAX machines by removing the abrasive strip from the drum and reversing it. To do this, remove the strip and use what was the trailing end as the starting end on the left (outboard) side of the drum. Reversing the strip will provide a fresh set of cutting edges on the drum. Keeping The Machine Clean. For best results, make cleaning the machine a regular shop procedure. Allowing excess build-up of dust and debris can adversely affect performance through the loading of the abrasives, slippage on the conveyor table, and/or the accumulation of material inside the drums which can throw off the center of balance. Leave the dust collector on when cleaning dust from the drums. Also brush the conveyor belt after cleaning operations. If not cleaned, the conveyor belt could allow stock to slip during sanding operations. Fig. 18. Cleaning abrasive strips. TROUBLESHOOTING YOUR SUPERMAX 19 TROUBLESHOOTING YOUR SUPERMAX Any operating problems with the SUPERMAX drum sander will likely occur most often during the period that you are becoming familiar with its components and their adjustments. If you are experiencing a problem affecting the machine’s sanding performance, check the following listings for potential causes and solutions; it may also pay to review the previous sections in this manual on setting up and operating your machine. TROUBLESHOOTING GUIDE: MOTORS P r oblem Possible Cause So l u t i o n Motors do not start. 1. Main power cord unplugged from receptacle. Plug in primary power cord. 2. Circuit fuse blown or circuit breaker tripped. Replace fuse or retrip breaker (after determining cause). 3. Drum motor thermal overload protector tripped (single phase only). Magnetic starter thermal overload protector tripped (SUPERMAX SE single and three phase models). Reset after allowing to cool; check circuit and/or reduce load or slow feed rate. 1. Inadequate circuit. Check electrical requirements. 2. Machine overloaded. Use slower feed rate and/or reduce depth of cut. 1. Motor not properly aligned. Loosen housing bolts, run motor, retighten bolts. 2. Shaft collar worn. Replace shaft collar (page 5). 3. Drive roller bent. Replace drive roller (page 31). 1. Excessive depth of cut. Reduce depth of cut; reduce feed rate. Drum motor overloads. Conveyor motor oscillates. Drum motor or conveyor gear motor stalls. 20 SUPERMAX OWNER’S MANUAL TROUBLESHOOTING GUIDE: MACHINE P r oblem Possible Cause So l u t i o n Abrasive strip comes off drum. 1. Slack in abrasive strip on drum. Remove slack in strip (page 10). 2. Abrasive improperly installed. Read section on abrasive installation (page 10). 1. Strip caught on inside edge of slot or on inboard side of drum. Readjust strip end in slot and/or trim abrasive edge. 2. Strip not cut properly. Recut and install abrasive strip (page 10). 1. Excessive depth of cut. Reduce depth of cut. 2. Excessive feed rate. Use slower feed rate. 3. Inadequate dust collection. Increase air flow at dust ports. 4. Inadequate abrasive. Use open-coat abrasive. 5. Stock fed at 90° angle. to drum. Angle stock to avoid resin line build-up. Conveyor rollers run intermittently. 1. Shaft coupling loose. Align shaft flats of gear motor and drive roller, and tighten shaft coupling set screws. Conveyor belt slips on drive roller. 1. Improper conveyor belt tension. Adjust belt tension (page 8). 2. Excessive depth of cut. Reduce depth of cut; reduce feed rate. 1. Excessive depth of cut. Reduce depth of cut. 2. Tension rollers too high. Lower tension rollers (page 28). 3. Excessive feed rate. Reduce feed rate. 4. Dirty or worn conveyor belt. Clean or replace conveyor belt (page 31). Abrasive strip loose. Abrasive loads up prematurely. Board slips on conveyor belt. TROUBLESHOOTING YOUR SUPERMAX 21 P r oblem TROUBLESHOOTING GUIDE: MACHINE (Continued) Possible Cause So l u t i o n 1. Belt out of adjustment. Readjust belt (page 8). 2. Drive or driven conveyor belt rollers misaligned. Readjust (page 8). 3. Conveyor table not flat and square. Readjust by leveling with leg glides (page 7). 4. Conveyor belt worn or defective. Replace conveyor belt (page 31). 5. Roller bushings elongated due to excessive wear. Replace bushings (page 31). Table height adjustment works improperly. 1. Improper adjustment of height control. Readjust height control (pages 9, 24, 26). Drum drive belt slips. 1. Improper V-belt tension. Increase drive belt tension. Knocking sound while running. 1. Bearing out of alignment. Realign bearing (page 33). 2. V-belt worn. Replace V-belt (page 32). 3. Loose weight in drum. Glue weight back in place. 4. Pulleys wobbling or out of round. Replace pulley (page 34) 5. Set screws loose in pulley or bearing. Retighten or replace set screws. 6. Abrasive fastener on drum loose (without abrasive strip in place). Insert abrasive paper, or replace fastener (page 10). 7. Bearing worn. idler pulley bearings). Replace bearing (page 33). Conveyor belt tracks to one side, or oscillates from side to side. 22 SUPERMAX OWNER’S MANUAL P r oblem TROUBLESHOOTING GUIDE: OPERATIONS Rippled sanded surface (non-uniform ripples). Possible Cause So l u t i o n 1. Uneven feed rate. Check for these conditions and refer to previous section, Troubleshooting: Machine. • See Selecting SandSmart Feed Rates (page 14). • Conveyor belt slipping on drive roller. • Board slipping on conveyor belt. • Conveyor gear motor stalling. • Excessive V-belt tension (page 5). • Set screw loose on shaft coupler between gear motor and conveyor. • Conveyor bushings dry; lubricate. Rippled sanded surface (uniformly spaced ripples). 1. Excessive feed rate. Reduce depth of cut or reduce feed rate 2. Excessive depth of cut. Reduce depth of cut or reduce feed rate. 3. Sander vibration. Check for these conditions: • Loose bolts or bearing and pulley set screws; retighten. • Dirty drum; clean inside. • Excessive V-belt tension; reduce tension (page 5). • Worn V-belt; replace (page 32). • Warped driven pulley, replace (page 34). TROUBLESHOOTING YOUR SUPERMAX 23 P r oblem TROUBLESHOOTING GUIDE: OPERATIONS (Continued) Sniping of wood (gouging near end of board). Burning of wood. Gouging of wood. Unsanded ridge along length of piece (sandpaper appears clean). Possible Cause So l u t i o n 1. Tension rollers set too far down. Reset tension rollers (page 28). 2. Stock not supported properly during infeed or outfeed. Support stock with roller stands, tables or benches. 3. Conveyor drive or driven rollers higher than conveyor bed. Readjust rollers (page 28). 1. Feed rate too slow. Increase feed rate. 2. Excessive depth of cut for grit used. Reduce depth of cut or increase grit coarseness. 3. Excess build-up on abrasive strips. Reduce depth of cut; clean strips or replace. 4. Abrasive is too fine. Replace with abrasive of coarser grit. 5. Abrasive strips overlapped. Rewrap strip without overlap. 6. Drum out of alignment. Realign drum (page 26). 1. Conveyor belt is too loose. Adjust belt tension (page 8). 2. Excessive depth of cut. Reduce depth of cut. 3. Wood slipping on conveyor due to lack of contact. Use alternate feeding procedure (page 17). 4. Abrasive is too fine. Replace with coarser grit. 1. Grit has been removed from backing. Avoid this area of drum, or change abrasive strips. 24 SUPERMAX OWNER’S MANUAL SERVICING YOUR SUPERMAX The basic adjustment procedures for your machine are covered under Setting Up Your SUPERMAX Sander, page 6. Review that section first. If following the general instructions does not solve a specific problem or result in smooth operation, also check Troubleshooting Your SUPERMAX, page 19. Below are suggested procedures to follow when more thorough readjustment or replacement is necessary. ADJUSTING HEIGHT CONTROLS Height adjustment problems may be the result of not loosening the set screws in the table support castings before attempting operation. (This is covered on page 5 of this manual, and also on the separate unpacking sheet which was shipped with your machine.) If the set screws were not loosened as instructed, do so now before proceeding further. Also make sure all moving parts of the height adjusting mechanism are well lubricated, including the miter gears, column tubes, and threaded height adjusting screws. When troubleshooting the height adjustment mechanism, first check the conveyor table for level (see page 7). Then test the height adjustment mechanism (See Fig. 19). If it does not operate easily, further adjustments may be necessary, as outlined below. Following these steps should result in smooth operation. Readjustment Procedure 1. Loosen the set screws located at the front of the table support castings (Fig. 19). 2. Lubricate thoroughly by applying penetrating lubricant to the table support castings where they contact the column tubes, and to all contact points of adjusting screws and cross bar (Fig. 20). Also apply oil or grease to the miter gears. 3. If the height adjustment feels stiff, check for misalignment of adjusting screw supports and the drum support castings which could cause binding on the adjusting screw rods (Fig. 19). These castings can be adjusted by loosening the set screws which secure them to the column tubes. Realign the adjusting screw supports by loosening the two set screws that hold them to the column tubes and rotate to the proper position. 4. The adjusting screw supports located immediately below the height adjustment handle and the H EIGHT ADJ. HANDLE DRUM SUPPORT CASTING TABLE SUPPORT CASTING HEX NUT & SET SCREW ADJ. SCREW SUPPORT M ITER GEAR Fig. 19. Table suppor t casting set screws. Fig. 20. Adjusting miter gears for proper mesh. SERVICING YOUR SUPERMAX 25 SHAFT COLLAR Fig. 21. Miter gear below adjusting screw suppor t. Fig. 22. Height controls on outboard side. left (outboard) drum supporting casting (Fig. 19) must both be set at the proper height along the column tubes so the height adjusting screws provide for proper miter gear alignment. Before adjusting these parts, tighten one set screw in the table support castings (Fig. 19) to hold the height adjusting screw in position during adjustment. Also check to see that the column tubes are centered inside the bore of the table support castings (Fig. 19). If not, loosen the casting bolts and tighten the set screws at the front of table support casting to center the tube. Retighten the bolts and loosen the set screws. distance should be 1/32" or less. If there is excessive space, move the adjusting screw support to the proper distance above the miter gear and retighten. Loosen the set screws in the table support castings (Fig. 19) and test for smooth operation. 5. If the height adjustment mechanism feels rough, check the miter gear (Fig. 20) alignment. The miter gears can be adjusted on their shafts by loosening the set screws on the gears. Check and adjust so that the gear mesh is not too tight or too loose, and that the gear teeth align with the opposing gear. Note that the shaft collars located on the cross bar (Fig. 21) should be adjusted to control the lateral movement of the cross bar to maintain accurate miter gear alignment and mesh. The mesh of the miter gears should be smooth and even. If not, adjust the gears for good mesh (Fig. 20). Measure the space between the miter gear and the adjusting screw support that holds the height adjusting screw in place (Fig. 21). The 6.. Next, check the position of the height adjusting screw rods. First raise the conveyor table. Then check the E-clip and washer at the top of the height adjusting screw on the left (outboard) side, and under the height adjustment handle on the right (inboard) side of the machine. On both sides, the washer and E-clip (or washer only) should be snug on the casting just below the washer. If there is a space between the washer and the casting, tighten one set screw in each of the table support castings. If one height adjusting screw is loose, remove the miter gear from the cross bar on that side. Turn down the threaded height adjusting screw rod until it is snug with the washer. Make sure both sides are snug on top. Reinstall the miter gear and tighten. Loosen the set screws in the table support castings and test for smooth operation. ADJUSTING TABLE SUPPORT CASTINGS If the conveyor table does not raise and lower easily, measure the distance between the top of the base column support and the bottom of the table 26 SUPERMAX OWNER’S MANUAL Fig. 23. Adjusting table suppor t castings. Fig. 24. Comparing dr um suppor t casting heights. support casting (Fig. 23) on both the right (inboard) side and the left (outboard) side of the machine. Compare these measurements; they should be within 1/16". If not, disengage the miter gear on the right (inboard) side of the cross bar. Adjust the conveyor bed height using the height adjustment handle to get the same measurement on both sides. Then re-engage the miter gear on the cross bar. If the conveyor table is still difficult to raise or lower, the table support castings may need to be recentered on the column tubes. To do this, loosen the 3/8" x 1" hex head bolts in each table support casting, adjust and tighten the set screws to hold the casting in position. Then tighten the hex head bolts and loosen the set screws. (see 1, Fig. 28, page 28). Raise the tension roller suspension assembly (2, Fig. 28) to its highest position so that the tension rollers are positioned higher than the bottom of sanding drum(s). Then retighten the four tension roller suspension bolts to hold the tension rollers in that position during drum alignment. ADJUSTING SANDING DRUMS After any adjustments of the castings on the columns, check to make sure the sanding drums are in alignment. To begin realignment of the sanding drum(s), first remove the abrasive strip from the drum. Release the V-belt tension from the motor by loosening the pinch bolt of the motor support casting (see 8, Fig. 5, page 6). Loosen two screws in lower belt guard. Slide the motor mount up the column tube and retighten the pinch bolt. After the feed table has been leveled, loosen all four tension roller suspension bolts Primar y Drum Alignment. Using a flat piece of wood or a steel rule as a thickness gauge, insert it between table and primary (front) drum and adjust the table height to gauge the thickness. Raise the table just so the drum can be barely turned by hand. Measure at both sides of the drum to check that the primary drum is parallel to the table. To adjust the primary drum alignment, loosen both set screws at the front of the right (inboard) drum support casting (Fig. 24) and raise or lower the casting on the column tube to correct drum alignment. Retighten the set screws and recheck the alignment. Note: Do not loosen the set screws of the left (outboard) drum casting as this will cause miter gear misalignment. Achieving a very precise primary drum alignment can be accomplished by disengaging the right (inboard) miter gear (Fig. 25) from the height adjustment cross bar, and using the height adjustment handle to finely raise or lower the inboard side of the table to achieve parallel align- SERVICING YOUR SUPERMAX 27 HEIGHT ADJ. HANDLE DRUM SUPPORT CASTING TABLE SUPPORT CASTING HEX NUT & SET SCREW M ITER GEAR Fig. 25. Adjusting primar y dr um. Fig. 26. Using thickness gauge during alignment. ment of the drum (see Adjusting Table Level, page 7). Note that if only fine adjustment of the primary drum alignment is required, these adjustment procedures can be used to correct alignment without relieving V-belt tension or adjusting tension rollers as described above. The above procedure is all that is required to align the drum on a single drum SUPERMAX sander. If yours is a dual drum machine, follow the procedure below. other side of drum in the same manner. Caution: Do not overtighten the hex nut of the indicator (Fig. 27). This can flare the brass bushing and render the indicator inoperable. Also, the secondary drum adjustment knobs should turn with a slight resistance to avoid any movement during operation. To adjust knob resistance, turn the knob clockwise to reveal the set screw on the Secondar y Drum Alignment. With the primary drum properly aligned, use the same thickness gauge and insert it between the secondary drum and the table from the back side of the machine. (Again, adjust the contact between the drum and guide so the drum can barely be turned by hand.) Measure at both sides of the drum to check that the secondary drum is parallel to the table. To adjust the secondary drum alignment, use the right and left drum adjustment knobs (Fig. 27) to raise or lower each side of the drum. At this point both the primary and secondary drums will be aligned parallel to the table and both drums will be at the same height above the table. Set the secondary drum adjustment indicators by loosening the hex nut (Fig. 27), moving the scale so that the zero mark is directly under the needle, and retightening the hex nut. Zero the indicator for ADJ. KNOB SHAFT COLLAR I NDICATOR NEEDLE I NDICATOR SCALE I NDICATOR HEX NUT Fig. 27. Secondar y dr um adjustment indicator. 28 SUPERMAX OWNER’S MANUAL 2 3 3 1 Fig. 28. Tension roller adjustment. 1. Tension Roller Suspension Bolts. 2. Tension Roller 3. Spring Retaining Scr e w s . 1 shaft collar below the bracket, then loosen the screw. Making sure the adjustment knob is tightly seated on top of the bracket, raise the shaft collar up against the bracket from below and tighten the set screw. Note: The nut of the rear bolt on the rear (secondary) drum bearing bracket should be backed off a quarter-turn from being fully tightened. This allows the lock washer under the rear bolt on the rear bracket to be depressed slightly, but not completely. After alignment is completed, lower the motor mount to re-establish V-belt tension. Tighten two screws in belt guard. sure can be adjusted two ways, either by loosening the tension roller spring retaining screws (see 3, Fig. 28) or by raising the height of the tension rollers. To adjust the tension rollers to eliminate snipe marks, use this two-step procedure: ADJUSTING TENSION ROLLERS Step 2. Lower the conveyor table by one full turn of the height adjustment handle. At this point, press down on the front (infeed) tension roller so it is resting on the table. Now tighten the front (infeed) tension roller suspension bolts. If there still is a snipe mark left on pieces being sanded, repeat Step 1 and Step 2, but in Step 2 lower the conveyor bed a half turn instead of a full turn. With the sanding drums properly aligned, raise the table to the bottom of the sanding drums. Loosen all four tension roller suspension bolts (see 1, Fig. 28). Lower the table by one full turn of the height adjustment handle. At this position the tension roller assembly should be resting on the table with the drums suspended slightly above the table. Then retighten the tension roller suspension bolts. Note: Too much tension roller pressure can cause snipe marks which are identified as a visible line running across the width of the board approximately 2 1/4" from the end of the board. If a snipe mark occurs on the trailing end of the board, adjust the infeed tension roller. Tension roller pres- Step 1. With the sanding drums properly aligned, loosen all four tension roller suspension bolts. Raise the table to the bottom of the sanding drum(s). The tension rollers should be resting firmly on the conveyor bed. Tighten only the two rear (outfeed) tension roller suspension bolts. Warning: Improperly adjusted tension rollers (i.e., those set too high, rendering them non-functional) could allow kick-back/slippage of pieces being sanded. SERVICING YOUR SUPERMAX 29 REPL ACING SANDING DRUMS Changing drums on the SUPERMAX is a relatively rare procedure, most often the result of external damage or damage resulting from improper settings for the stock being sanded. To begin, disconnect power to sander. Remove the sandpaper on the drums and level the sanding drums to each other. Next, loosen the pinch bolt of the motor support casting, loosen two screws in lower belt guard, raise the motor, and retighten the pinch bolt. With this done, follow the steps below for dual drum sanders. The procedure is basically the same for single drum sanders except there is only one driven pulley and drum. Disassembly Procedure 1. Disengage the outer belt guard cover by removing the four 10-32 screws and the two 5/16" x 1/2" bolts holding it in place. (Fig. 29). Take the V-belt off driven pulleys. 2. Level the drums to each other (see pages 7 and 8 in this manual). Then raise the conveyor bed until the drum(s) rest on the conveyor bed. 3. Remove the four 3/8" x 2 1/4" bolts from the drum support casting on the right side (see Fig. Fig. 29. Removing outer belt guard. 30). Remove on/off switch, bracket, and depth gauge. 4. Remove the top two 3/8" x 2 1/4" bolts from the drum support casting on the left (outboard) side of the sander. Loosen the bottom two 3/8" x 2 1/4" bolts from the left drum support casting, but do not remove them. 5. Lift the right (inboard) side of drums and place a 2x6 on edge under the drums (Fig. 32). Loosen and remove the V-belt pulleys from drum shafts. Impor tant: Make sure to note the location of the pulleys. Also measure the distance from pulley edge to the drum support casting to use as a reference when reinstalling pulleys so they will be properly aligned. 6. Loosen the set screws in the two V-belt pulleys and remove the pulleys. Next, loosen the two set screws in each of the four bearing collars (Fig. 33). Now remove the sanding drum support brackets that hold the bearings (Fig. 34). Remove the sanding drums at this time and install the new drums. If the bearings need replacing, replace them at this time (see page 33). Fig. 30. Removing bolts from dr um suppor t casting. 30 SUPERMAX OWNER’S MANUAL Reassembly Procedure 1. To assemble the unit after replacing drums, install the sanding drum support brackets. Slide the drums through the bearings but do not tighten the set screws in the bearings yet. Install the V-belt pulleys, but don’t tighten the set screws yet. 2. Remove the 2x6 from the conveyor bed at this time. Align the cross brace and the dust cover at Fig. 31. Drum suppor t casting bolts (outboard side). this time. Install the four bolts on the right (inboard) side. Install the on/off switch with the infeed bolts and two bolts on the left (outboard) side of the sander and tighten securely. 3. Tighten the two set screws in each of the four bearing collars. Spin the drums by hand to check if they spin freely. Fig. 32. Suppor ting dr ums with 2x6 on edge. DRUM SUPPORT B RACKET Fig. 33. Loosening dr um bearing set screws. Fig. 34. Removing sanding dr um suppor t bracket. SERVICING YOUR SUPERMAX 31 4. Align the V-belt pulleys with the pulley on the motor and then tighten the set screws in the V-belt pulleys. Spin the drums by hand to make sure the pulleys are in proper alignment. 5. Check the alignment of the front drum to the conveyor table. If they are not parallel, level the front and then the rear drum (see pages 7 and 8) before proceeding further. TAKE-UP SCREW 6. Readjust the tension of the V-belt by sliding the motor down and then tightening the pinch bolt in the motor support casting. Make sure all pulleys are aligned and all bolts tight before using the sander. 7. Reinstall the outer belt guard using the two 5/16" x 1/2" hex head bolts. Reinstall the lower belt guard using the two 10-32 screws and the middle, inner guard using two 10-32 screws. REPL ACING CONVEYOR BELTS To replace the conveyor belt, the conveyor assembly must be removed from the machine. Lower the conveyor table to its lowest position with the height adjustment handle. Remove the bottom cover from control box, rotate shaft to access set screws in shaft coupler. Important: Disconnect power to sander. Loosen one set screw. Remove the four 5/16" bolts holding the conveyor motor control box base bracket (Fig. 45). Remove conveyor motor control box and place on dust cover. Loosen the conveyor take-up screws (Fig. 35 and Fig. 36) to relieve belt tension and slide the driven roller fully inward. Remove the four bolts that attach the conveyor assembly to the table mount brackets (see Fig. 36). Lift the conveyor and remove it from the machine by sliding the conveyor out toward the front of the machine. Avoid tearing the belt on any edges underneath the conveyor bed during removal. Reverse the procedure for re-installation. Note: If the conveyor belt continually tracks to one side of the machine, first try reversing the belt on the conveyor bed. If this doesn’t remedy the problem, place a level on the conveyor bed to make sure the conveyor bed is not twisted. If it is twisted, see page 7 for instructions on squaring up the bed. If squaring up the bed does not remedy the problem, proceed with the steps below: TABLE MOUNT B RACKET Fig. 35. Conveyor belt replacement. Step 1. Check the conveyor drive and driven roller to make sure they are parallel to the surface of the conveyor bed. To do this, first center the conveyor belt on the bed. Then lay a straight-edge on the exposed edge of the conveyor table on the left (outboard) side, extending it over the drive roller, then driven roller. Note the distance between the drive roller then driven roller and the straight-edge. CONVEYOR MOUNTING BOLT Fig. 36. Tensioning and tracking conveyor belt. 32 SUPERMAX OWNER’S MANUAL V-BELT REMOVED TRANSFER ROD Fig. 37. Removing belt guard and transfer rod. Fig. 38. Removing main motor V-belt drive. Step 2. Now repeat Step 1 on the right (inboard) side of the conveyor. Compare the measurements from side to side. If they are not equal, loosen one of the brackets that hold the drive or driven roller in place. Tip this bracket until the distance between the drive or driven roller and the straightedge are equal from side to side, then tighten the bracket. 3. Remove the miter gear from the right (inboard) side of the transfer rod. Loosen the shaft collar on the left (outboard) side of the rod, and pull the rod back enough so the V-belt can be removed. Note the routing of the old V-belt; now remove the old V-belt and replace it with the new V-belt. REPL ACING V-BELT To change the V-belt on the SUPERMAX, first unplug machine from the outlet. Remove two screws in lower section of belt guard and loosen the pinch bolt of the motor support casting. Raise the motor and retighten the pinch bolt. The procedure is the same for single drum sanders except that there is one driven pulley instead of two. V-Belt Removal 1. Remove the lower outer belt cover by removing the four 10-32 screws holding it in place (see Fig. 29 and 37). Remove the two 5/16" x 1/2" hex head bolts holding it in place; pull the middle cover to the left. Take the V-belt off the pulley (Fig. 38). 2. Loosen the pinch bolt of the motor support casting, raise the motor, and re-tighten pinch bolt. Machine Reassembly 1. To reassemble the unit after replacing the Vbelt, first place the transfer rod back through the machine. Tighten the shaft collar. Reinstall the miter gear on the transfer rod, making sure the set screw is centered on the flat of the rod. 2. Adjust the tension on the V-belt by sliding the motor down and then tightening the pinch bolt in the motor support casting. Adjust so the belt deflects about 1/2" between the pulleys when pressed. Excessive tension can increase motor load and decrease bearing life, while a loose belt can reduce operating efficiency and shorten belt life. 3. Reinstall the outer and middle belt guard using the two 5/16" x 1/2" hex head bolts and the four 10-32 screws. SERVICING YOUR SUPERMAX 33 4. Make sure that the pulleys are in alignment by holding a straightedge across their flat sides and adjusting to it. Also check that all bolts are tight before using the sander. ROTATING/REPL ACING DRUM BEARINGS Replacing the permanently lubricated drum bearings on the SUPERMAX sander is a relatively straight-forward procedure. Bearings should be replaced when they allow excessive play of the drum, make excessive noise, or otherwise indicate failure. Note that if clicking noises in the bearings are a problem, rotating may be a solution instead of replacement, as follows (See Fig. 40): Rotating Bearings Step 1. Loosen the set screws in the bearing collar. Leave the allen wrench in one of the set screws. Then rotate the drum within the bearing and tighten the set screws. Step 2. If the clicking persists, or if the drum shaft is tight in the bearing and cannot rotate, then loosen the two bolts holding the bearing and the flange for the bearing. Now repeat Step 1. After the drum is rotated within the bearing, tighten the flanges first and then the set screws. Note: After tightening the rear bolt in the flange, loosen it approximately 1/4 turn, which allows the rear drum to pivot. After the machine has run for a half hour, stop to check that the set screws and bearing bolts are tight. The general procedure outlined below suggests replacing bearings on the left (outboard) side, one at a time, starting with the rear drum of dual drum sanders, then moving to the front drum. Then, if needed, proceed to the right (inboard) side, also working on the rear drum of dual drum sanders first, then the front drum. Fig. 39. Suppor ting dr ums to remove bearings. 3. Loosen the pinch bolt of the motor support casting and raise the motor to loosen the V-belt. 4. Next, level the drums to each other (see pages 7 and 8 in this manual). Then raise the conveyor bed until the drum(s) rest on the conveyor bed. With this done, follow the steps below: Disassembly Procedure 1. To begin the procedure in all cases, disconnect power to sander. 2. Remove the outer belt guard cover by removing the two 5/16" x 1/2" hex head bolts holding it in place, then the four 10-32 screws in the lower half. Slide the middle section back and the outer guard to the side. Fig. 40. Locating bearing set screws. 34 SUPERMAX OWNER’S MANUAL Fig. 41. Removing rear dr um bearing. Fig. 42. Removing front bearing (inboard side). Bearing Replacement (Left Side). If replacing all bearings, work first on the bearings on the left (or outboard) side of the sander first, one at a time, starting with the rear drum on dual drum sanders. (Follow Steps 1 through 3 for the bearing on the left side of single drum sanders, but do not loosen the rear bolt as instructed in Step 3.) over-tighten the nut that holds the indicator in place (see exploded view, page 43). 1. Begin by removing the outer half of the bearing flange. Loosen the set screws in the bearing collars and remove the bearing (Fig. 41). 2. If the shaft of the drum is rough from the set screws, use emery cloth or sandpaper to smooth down any raised edges. Slide the new bearing on the shaft, but do not tighten the set screws yet. Bearing Replacement (Right Side). If the left (outboard) bearings are the only ones that need changing, proceed to reassemble the unit. You can check the drums at this point by lowering the conveyor bed and spinning the drums by hand. This will help determine if the inboard bearing(s) need to be changed to eliminate noise or excessive play in the drum. 1. With the drums resting on the conveyor bed, proceed as follows. Remove the four 3/8" x 1 1/4" bolts from the drum support casting on the right side, remove the on/off switch and depth gauge with the bolts. 3. Install the outer half of the original bearing flange and tighten the bolts on the rear drum. After tightening the rear bolt in the flange, loosen it approximately 1/4 turn, which allows the rear drum to pivot. Then tighten the set screw in the bearing collar (Fig. 43). 2. Next, remove the upper two 3/8" x 1 1/4" bolts from the drum support casting on the left (outboard) side of the sander. Loosen the bottom two 3/8" x 1 1/4" bolts from the left drum support casting, but do not remove them. 4. Now move to the front drum and repeat Steps 1 through 3, but do not loosen the rear bolt as instructed in Step 3. Impor tant: Be sure to note the sequence of parts used for the rear drum indicator assembly. Also, when reinstalling, do not 3. Lift the right (inboard) side of drums and place a 2x6 on edge under the drums. Loosen and remove the V-belt pulleys from drum shafts (see Fig. 39). Impor tant: Make sure to note the location of the pulleys. Also measure the distance from SERVICING YOUR SUPERMAX 35 Fig. 43. Removing rear bearing (inboard side). Fig. 44. Installing rear bearing (inboard side). pulley edge to the drum support casting to use as a reference when reinstalling pulleys so they will be properly aligned. conveyor system. (For instructions on this procedure, see pages 7 and 8 of this manual.) Make sure the drums are parallel to each other. 4. Replace bearings by following Steps 1 through 4 under Bearing Replacement (Left Side) above (Fig. 41-44). 3. Reinstall the V-belt on the motor pulley and adjust its tension. Then reinstall the pulley guard. 5. Reinstall V-belt pulleys on the drum shafts, making sure they are located in the same position as before. Doublecheck this alignment after the drums have been bolted back in place, using the measurement from Step 3 above. 4. Test-run the sander before sanding stock to recheck that all is operating properly and is aligned before sanding good stock. Also, stop the sander after a couple hours of use and check the bolts and set screws to make sure they are seated properly. 6. Lower the drums by removing the 2x6. Reinstall the six 3/8" x 1 1/4" bolts in the drum support castings and tighten them. Install the on/off switch and depth gauge with the two inboard bolts. Reassembly Procedure 1. Lower the conveyor and spin the drums by hand to make sure the drum shaft is not binding in the bearing. If the bearings bind, loosen the set screws and the bearing flange for one bearing at a time. Spin the drum within the collar, then tighten the set screws and then the bearing flange (Fig. 40). 2. Next, check the alignment of the drums to the P ROSCALE DE P T H GAUGE Fig. 45A. Conveyor control box, on/off switch and ProScale SUPERMAX SE. 36 SUPERMAX OWNER’S MANUAL Fig. 45. Conveyor control box and on/off switch, SUPERMAX HD. REPL ACING ELECTRICAL COMPONENTS To replace either the variable-speed SandSmart control, the on-off switch, or the conveyor motor, use the following disassembly procedure (Fig. 45 and 45A): First disconnect the power supply to the Lovato Single phase wiring diagram. machine. Next, remove the bottom plate from the control box. Loosen the set screw in the shaft coupler, and then remove the four 5/16" bolts that hold the conveyor motor assembly in place (Fig. 45). Next, remove the assembly from the machine, then turn it upside down to disconnect the leads from the components to be removed. To replace the SandSmar t control: remove the knob by loosening screw and remove nut that was under knob. Turn housing over, and remove the nuts holding control board in place. Lift control board from housing. Install the new controller, referring to the correct electrical diagram and reverse the disassembly procedure. To replace the on-off switch: remove the two screws holding cover in place. Pull switch from box. Disconnect wire leads from switch and remove cover plate from switch. Referring to the correct electrical diagram, reverse the disassembly procedure. To replace the gear motor: disconnect the three wire leads from the controller. Disconnect the plastic grommet protecting the wires passing through the sheetmetal. Then remove the four set screws that hold the motor to the sheetmetal bracket. Remove the old motor and install the new motor. Referring to the correct electrical diagram, reverse the disassembly procedure. SUPERMAX TECHNICAL DATA 37 SUPERMAX SPECIFICATIONS SUPERMAX 25 & 37 (single drum); SUPERMAX 25x2 & 37x2 (dual drum) Dimensions: Model 25 & 25x2: Height: 43 3/4"; Width: 46"; Depth: 31" Model 37x2: Height: 49"; Width: 58"; Depth 31" Dust Hood: Model 25 & 25x2: 4" vacuum port, hinged back. Model 37 & 37x2: Two 4" vacuum ports, hinged back. Drums: Bearings: Model 25: 5" x 25"; Model 25x2: Two 5" x 25"; Model 37: 5" x 37"; Model 37 x 2: Two 5" x 37" All drums extruded aluminum, precision machined and balanced, 1,600 RPM. All Models: 1" sealed, permanently lubricated, flanged ball bearings. Abrasive Strips: Tapered aluminum oxide or ceramic cloth-backed abrasive strips recommended. Fasteners accept any grit. No felt, velcro, or adhesive necessary. One strip included. Conveyor Bed: All Models: Steel conveyor bed reinforced with four steel cross sections. Conveyor Motor: Conveyor Belt: Stand Construction: Drive Motor: Minimum Stock Length: Height Adjustment: Stock Thickness Capacity: Shipping Weight: Dust Collection: Three phase wiring diagram. All Models: 100 in-lbs. torque, direct-drive DC motor. Infinitely variable from 0 to 15 feet per minute with SandSmart. All Models: 100-grit abrasive conveyor belt included. All Models: Cast aluminum, zinc-plated steel. Column tubes are centerless ground. All Models: 5 HP; TEFC; 1,740 RPM; 208-230 volts; 60 HZ. Models 25 & 37: 2 1/2"; Models 25x2 & 37x2: 3 1/2" All Models: 3/32" per turn; Depth Gauge included. 25 and 25x2: 6"; 37 and 37x2: 12" Model 25: 350 lbs.; Model 25x2: 375 lbs.; Model 37: 400 lbs.; Model 37x2: 455 lbs. Mandatory for all models. 38 SUPERMAX OWNER’S MANUAL SUPERMAX STAND ASSEMBLY PARTS LIST Ref. Number 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 Description HEIGHT ADJUSTMENT HANDLE ASSEMBLY 3/16"x1" ROLL PIN 5/8" I.D. OILITE WASHER 3" PLASTIC COLUMN TUBE CAP ADJ. SCREW SUPPORT CASTING 1/4"–20x1/2" SOCKET HEAD SET SCREW 5/16"–18x3/8" SOCKET HEAD SET SCREW PLASTIC CAP SELF TAPPING SCREW DEPTH GAUGE POINTER DEPTH GAUGE SCALE DEPTH GAUGE (NOT SHOWN) DRUM SUPPORT CASTING – SINGLE – DUAL DEPTH LOCK CASTING INBOARD TABLE SUPPORT CASTING – SINGLE – DUAL 5/16"–18 HEX NUT 5/16" SAE WASHER 5/16"–18x3/4" BRASS TIPPED SET SCREW LOCKING KNOB OUTBOARD TABLE SUPPORT CASTING – SINGLE – DUAL TABLE MOUNT BRACKET 3/8"–16x1" HEX HEAD BOLT 5/16" WROUGHT WASHER 3/8"–16 FLANGE LOCK NUT INBOARD HEIGHT ADJ. SCREW MITER GEAR 1/2" I.D. OILITE BUSHING COLUMN TUBE COLUMN TUBE 1/2-13x1/2" SOCKET HEAD SET SCREW SHAFT COLLAR 1/2" I.D. TRANSFER ROD MOTOR MOUNT MOTOR SUPPORT CASTING 3/8"–16x1 1/2" HEX HEAD BOLT LEG CASTING LEG CASTING COLUMN BASE CASTING LEVELING FEET 3/8"–16 HEX NUT BASE SUPPORT BRACKET RETAINING RING OUTBOARD HEIGHT ADJ. SCREW Part Number SM25x2 Both SM37x2 Models Qty./ Unit 31-0020 20-0772 50-3080 80-4015 30-1112 10-2804 10-2903 80-4013 10-3905 1 1 2 2 3 6 4 3 2 1 1 1 2 2 2 1 1 4 4 4 2 1 1 2 18 37 24 1 4 4 2 2 2 2 1 1 1 9 4 4 2 4 8 1 1 1 40-1102 40-1101 94-1654 30-1260HR 30-5106 30-5206 30-1112 30-5104 30-5204 12-0003 11-0206 10-9906 81-3132 30-5105 30-5205 40-0025 40-4242 10-0205 11-9103 12-0209 30-1212 30-1212HR 20-1101 50-3107 30-1236 30-3044 10-8905 20-1103 30-1213 30-3117 40-0106 30-5107 10-9207 30-1102 30-1103 30-1101 20-0655 12-0005 40-0230 40-4241 20-0752 30-1211 30-1211HR SUPERMAX SE STAND ASSEMBLY 39 40 SUPERMAX OWNER’S MANUAL SUPERMAX SINGLE DRUM HEAD ASSEMBLY PARTS LIST Ref. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Description DUST COVER DUST COVER HANDLE #8x1/2" HEX HEAD SELF TAPPING SCREW 1/4"–20x1/2" ROUND HEAD MACH SCREW 1/4" INTERNAL TOOTH LOCK WASHER DUST COVER MOUNT HINGE 1/4" SAE WASHER 1/4"–20 HEX NUT 3/8"–16x1" HEX HEAD BOLT 5/16" WROUGHT WASHER DRUM MOUNTING BRACKET 3/8"–16 FLANGED LOCK NUT 5/16"–18x1" CARRIAGE HEAD BOLT DRUM BEARING 1/4"–28x1/4" SET SCREW (BEARING) #8–32x1" PHILLIPS FILLISTER HEAD SCREW COMPRESSION SPRING RIGHT TENSION ROLLER SUSPENSION BKT. LEFT TENSION ROLLER SUSPENSION BKT. TENSION ROLLER BASE BKT. #8–32 SQUARE NUT 5/16" SAE WASHER 5/16"–18 HEX NUT 5/16"–I.D. OILITE BUSHING TENSION ROLLER OUTBOARD ABRASIVE FASTENER #6–32x3/8" FLAT HEAD PHILLIPS SCREW SANDING DRUM INBOARD ABRASIVE TAKEUP FASTENER 1/4"x1" KEY STOCK UPPER INNER BELT GUARD #10–24 RETAINING NUT DRIVEN PULLEY 5/16"–18x3/8" SET SCREW (PULLEY) MIDDLE INNER BELT GUARD BELT GUARD COVER #10–24x3/8" SLOTTED HEX HEAD SCREW Part Number SM25 Both SM37 Models 40-0525 40-4237 80-2841 10-3904 10-3205 11-0504 40-0240 40-4243 40-0225 11-0205 12-0001 10-9205 11-9103 40-0210 12-0209 10-1204 50-3057 10-8602 10-3107 20-3268 40-0302 40-0303 40-0304 12-0102 11-0206 12-0003 50-3105 30-1205 30-3119 21-1173 10-3003 30-1200 30-3100 21-1172 20-0762 40-3050 20-1155 50-0502 10-8903 40-3061 40-3060 10-3803 Qty./ Unit 1 1 2 8 8 1 2 8 8 8 8 2 8 4 2 4 4 4 2 2 2 4 4 4 4 2 1 2 1 1 1 1 4 1 1 1 1 4 SUPERMAX SINGLE HEAD DRUM ASSEMBLY 41 42 SUPERMAX OWNER’S MANUAL SUPERMAX DUAL DRUM HEAD ASSEMBLY PARTS LIST Ref. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Description Part Number SM25x2 Both SM37x2 Models Qty./ Unit DUST COVER DUST COVER HANDLE #8x1/2" SELF TAPPING SCREW 1/4"–20x1/2" ROUND HEAD MACH SCREW 1/4" INTERNAL TOOTH LOCK WASHER DUST COVER MOUNT HINGE 1/4" SAE WASHER 1/4"–20 HEX NUT 3/8"–16 x1" HEX HEAD BOLTS 5/16" WROUGHT WASHER 3/8"–16 FLANGED LOCK NUT 1/4"-28x1/4" SOCKET HEAD SET SCREW (BEARING) 5/16"–18x1" CARRIAGE HEAD BOLT 5/16"–18x1 1/4" HEX HEAD BOLT 5/16" SAE WASHER 5/16" I.D. SPACER DRUM BEARING OUTBOARD DRUM MOUNT BKT. 5/16"–18 HEX NUT SECONDARY DRUM ADJ. KNOB 5/16" I.D. SHAFT COLLAR WITH SET SCREW OUTBOARD SECONDARY DRUM ADJ. BKT. 5/16" LOCK WASHER OUTBOARD SECONDARY DRUM INDICATOR BRASS SPACER 3/8" SPRING WASHER EXTENSION SPRING 1/4" x 1" KEY STOCK OUTBOARD INDICATOR NEEDLE OUTBOARD ABRASIVE FASTENER #6–32x3/8" FLAT HEAD PHILLIPS SCREW SANDING DRUM INBOARD ABRASIVE TAKEUP FASTENER INBOARD INDICATOR NEEDLE INBOARD SECONDARY DRUM INDICATOR INBOARD SECONDARY DRUM ADJ. BKT. 1/2"–13x2" HEX HEAD BOLT 1/2" INTERNAL TOOTH LOCK WASHER INBOARD DRUM MOUNT BKT. 5/16"–18 RETAINING NUT 1/2" I.D. SPACER IDLER PULLEY 1/2" SAE WASHER 1/2" LOCK WASHER 40-1525 1 1 2 8 8 1 2 8 8 8 8 8 8 6 2 10 2 4 1 8 2 2 1 2 1 2 2 2 2 1 2 4 2 2 1 1 1 1 1 1 2 1 1 1 1 40-3237 80-2841 10-3904 10-3205 11-0504 40-0240 40-4243 40-0225 11-0205 12-0001 10-9205 11-9103 12-0209 10-8602 10-1204 10-9106 11-0206 30-1305 50-3067 40-0519 12-0003 80-3135 20-1102 40-0527 11-0010 95-1659 30-1303 20-1165 20-3210 20-0762 40-0531 21-1173 10-3003 30-1200 30-3100 21-1172 40-0530 95-1660 40-0526 10-0407 11-0508 40-0520 20-1159 30-1304 50-1258 11-0209 11-0013 (Continued on page 44) SUPERMAX DUAL DRUM HEAD ASSEMBLY 43 44 SUPERMAX OWNER’S MANUAL SUPERMAX DUAL DRUM HEAD ASSEMBLY PARTS LIST (Cont'd) Ref. Number 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Description 1/2"–13 HEX NUT DRIVEN PULLEY 5/16"–18x1/2" HEX HEAD BOLT BELT GUARD COVER #8-32x1" PHILLIPS FILLISTER HEAD SCREW COMPRESSION SPRING 5/16"–18x3/4" CARRIAGE HEAD BOLT #8-32 SQUARE NUT TENSION ROLLER BASE BKT. TENSION ROLLER SUSPENSION BKT., RIGHT TENSION ROLLER SUSPENSION BKT., LEFT 5/16" I.D. OILITE BUSHING TENSION ROLLER MIDDLE INNER BELT GUARD #10–24 RETAINING NUT #10–24x3/8" SLOTTED HEX HEAD SCREW 5/16"–18 FLANGED LOCK NUT 5/16"–18x3/8" SET SCREW (PULLEY) BELT GUARD PLATE (NOT SHOWN) Part Number SM25x2 Both SM37x2 Models Qty./ Unit 12-0009 50-0502 10-9101 1 2 2 1 6 6 4 6 2 3 3 6 3 1 2 4 6 2 1 80-1028 80-1038 10-3107 20-3268 10-1203 12-0102 40-0306 40-0302 40-0303 50-3105 30-1205 30-3119 41-1028 20-1155 10-3803 12-0207 10-8903 41-1010 SUPERMAX CONVEYOR & MOTOR PARTS LIST Ref. Number 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 Description DRIVEN ROLLER 1/2" I.D. SQUARE OILITE BUSHING TAKEUP SLIDE 5/16" SAE WASHER 5/16"–24 FLANGED NUT WRENCH TAKEUP BASE BRACKET 3/8"–16x1" CARRIAGE BOLT 5/16"–24x3" STUD 3/8"–16 NYLON INSERT LOCK NUT 3/8" SPRING WASHER SIDE RAIL ROLLER SUPPORT BRACKET RUBBER COVERED DRIVE ROLLER 3/8"–16x3/4" CARRIAGE BOLT 3/8" FLANGED LOCK NUT CONVEYOR BED SIDE RAIL Part Number SM25 Both SM37 Models 30-3103 30-3104 50-3109 40-4108 11-0206 12-0308 40-0375 40-4107 10-1302 30-1306 12-8005 20-1165 40-4105 40-4109 30-3106 30-3107 10-1301 12-0209 40-4101 40-4201 40-4106 Qty./ Un i t 1 4 2 2 6 2 2 16 2 4 8 1 1 1 4 16 1 1 (Continued on page 46) SUPERMAX CONVEYOR & MOTOR 45 46 SUPERMAX OWNER’S MANUAL SUPERMAX CONVEYOR & MOTOR PARTS LIST (Cont’d.) Ref. Number 20 21 22 23 24 25 25 26 27 27 28 29 30 30 31 32 33 35 36 36 37 38 39 39 40 41 42 43 44 45 46 46 47 48 49 50 51 52 53 54 54 55 56 56 57 58 59 Description BOTTOM COVER #10–24 RETAINING NUT #10–24x3/8" SLOTTED HEX HEAD SCREW CONTROL BOX BASE BRACKET 1/4"–20x1/2" ROUND HEAD MACH SCREW SWITCH BRACKET, SINGLE PHASE SWITCH BRACKET, THREE PHASE SWITCH BOX ON/OFF SWITCH (DRUM), SINGLE PHASE ON/OFF SWITCH (DRUM), THREE PHASE 1/4"–20 HEX NUT LARGE STRAIN RELIEF CORD SET, SINGLE PHASE CORD SET, THREE PHASE #6-32x1–1/4" PHILLIPS PAN HEAD SCREW KNOB SMALL STRAIN RELIEF 180-VOLT GEAR MOTOR MAIN CORD SET, SINGLE PHASE MAIN CORD SET, THREE PHASE 5/16"–18x1/2" HEX HEAD BOLT CONTROL HOUSING SANDSMART CONTROLLER, SINGLE PHASE SANDSMART CONTROLLER, THREE PHASE #6-32 NUT #6 WASHER 5/16"–18 RETAINING NUT 1/4"–20x1/4" SOCKET HEAD SET SCREW COUPLING (CONVEYOR) 5/16"–18x3/4" CARRIAGE BOLT 5 H.P. TEFC ELECTRIC MOTOR, SINGLE PHASE 5 H.P. TEFC ELECTRIC MOTOR, THREE PHASE 3/8" WROUGHT WASHER 5/16"–18 FLANGED LOCK NUT LOWER INNER BELT GUARD #10–24 RETAINING NUT 4 1/2" DRIVE PULLEY 1/4"x1" KEY STOCK 5/16"–18x3/8" SOCKET HEAD SET SCREW CORD SECTION, SINGLE PHASE CORD SECTION, THREE PHASE RETAINING CLIP V-BELT– SINGLE DRUM, 25” – DUAL DRUM, 25” V-BELT– DUAL DRUM, 37” 5/16" I.D. THIN WASHER 5/16"–32 JAM NUT CONVEYOR BELT (NOT SHOWN) Part Number SM25 Both SM37 Models 40-4116 20-1155 10-3803 40-4115 10-3205 40-5005 40-0124 72-5400-2 72-5400-1 72-1311 12-0001 72-1404 72-5315 72-5305 10-3902 72-1270-1 72-6102 71-1171 72-5430 72-5305 10-9101 40-5013 72-2280 72-2270 12-9001 11-0202 20-1159 10-8802 30-3102 10-1203 70-0507 70-1503 11-0104 12-0207 40-1000 20-1157 50-0450 20-0762 10-8903 72-5315 72-5305 72-6210 50-2021 50-2023 50-2030 72-1270-3 72-1270-4 60-0324 60-0337 Qty./ Unit 1 2 2 1 3 1 1 1 1 1 3 5 1 1 2 1 1 1 1 1 4 1 1 1 2 2 4 2 1 4 1 1 2 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 SUPERMAX TECHNICAL DATA 47 SUPERMAX ACCESSORY & SUPPLY CHECKLIST ITEM # DE S C R I P T I O N QTY. SUPER MAX OPTIONS 98-0130 98-0070 CASTER SET: Heavy duty, roll & swivel lock. (Set of 4) RACK-N-ROLL: Abrasive storage system. AB R A S I V E S Resin bond, non-adhesive abrasive cloth strips. • Ready-To-Cut 60 grit and finer covers 25" dr um 12 times, 37" dr um 8 times • Ready-To-Cut 36 grit covers 25" dr um 9 times, 37" dr um 6 times • Ready-To-Wrap precut grit includes 3 strips for 25" dr um, 2 strips for 37" dr um Pre-Cut 25" 37" 60-5024 60-7024 60-5036 60-7036 60-5060 60-7060 60-5080 60-7080 60-5100 60-7100 60-5120 60-7120 60-5150 60-7150 60-5180 60-7180 60-5220 60-7220 60-5000 n/a 60-0505 PreMarked 60-9036 60-9060 60-9080 60-9100 60-9120 60-9150 60-9180 60-9220 n/a Size and Description 24 GRIT: Surface rough sawn boards, stock & glue removal 36 GRIT: Surface rough sawn boards, stock & glue removal. 60 GRIT: Surfacing and dimensioning boards, trueing warped boards. 80 GRIT: Surfacing, light dimensioning, remove planer ripples. 100 GRIT: Light surfacing, remove planer ripples. 120 GRIT: Light surfacing, minimal stock removal. 150 GRIT: Finish sanding, minimal stock removal. 180 GRIT: Finish sanding, not for stock removal. 220 GRIT: Finish sanding, not for stock removal. Assortment: 1 strip each of 36, 80, 120 grit. ABRASIVE CLEANING STICK Specialty abrasives are also available. SUPER MAX P OWER FEED CONVEYOR BELTS T Y P E 1: 100 gr i t a b r a s i v e s ur f a c e w i t h r einfor ced film backing. T YPE 2: Polyurethane roughtop sur face with monofilament backing. T Y PE 1 60-0324 60-0337 T Y PE 2 61-1004 61-1007 24" Power Feed Bed with 2" diameter Drive Roller. 36" Power Feed Bed with 2" diameter Drive Roller. Note: It is our policy to not sell direct in an DEALER NEAREST YOU: area that is ser ved by a SuperMax Tools dealer. ______________________________________ For information on the dealer nearest you, ______________________________________ call 651-454-3401 or email [email protected] ______________________________________ or visit our website at www.supermaxtools.com 2 YEAR WARRANT Y Limited warranty. We will provide replacement par ts which are found to be defectiv e i n m a t e r i a l s o r w o r kmanship. CAUTION: IMPORTANT SAFET Y INFORMATION FOR SAFE SANDING OPERATION, FOLLOW THESE GUIDELINES: ■ BECOME FAMILIAR WITH THE PROPER OPERATIONAL PROCE DURES FOR USING THIS MACHINE. ■ ALWAYS BE SAFET Y CONSCIOUS WHEN OPERATING THE MACHINE. ■ ALWAYS WEAR EYE PROTECTION WHILE OPERATING THE SANDER. ■ ALWAYS FEED STOCK AGAINST THE ROTATION OF THE DRUM(S). ■ NEVER PL ACE HANDS UNDER THE DRUM(S) OR DUST COVER. ■ NEVER OPERATE SANDER WITHOUT ITS DUST COVER OR DRUM AND BELT GUARDING IN PL ACE. ■ KEEP HANDS AND CLOTHING AWAY FROM OPERATING DRUM(S), BELT AND PULLEYS. ■ ALWAYS MAINTAIN CONTROL OF STOCK TO AVOID KICKBACK; KNOW HOW TO PREVENT IT. ■ ALWAYS DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICING OR ADJUSTMENT OF THE MACHINE. ■ DO NOT MODIFY THIS MACHINE: MODIFICATIONS ARE DONE AT THE OWNER’S RISK AND ALSO WILL VOID THE MANUFACTURER’S WARRANT Y. ■ FOR CUSTOMER SERVICE AND QUESTIONS ABOUT THE OPERA TION OR MAINTENANCE OF THIS MACHINE, PLEASE CALL YOUR AUTHORIZED PERFORMAX DEALERSHIP. PART NO. 92-3700D © COPYRIGHT 2006 PRINTED IN USA